The Need

Modern structural systems increasingly demand integrated sensing, actuation, and health monitoring capabilities, particularly in aerospace, automotive, and advanced manufacturing. However, current approaches rely on separately fabricated sensors that are later attached to structures, introducing reliability concerns, added weight, and manufacturing complexity. Additionally, existing additive manufacturing methods are not well-suited to incorporate functional smart materials without degrading their properties. There is a critical need for scalable fabrication methods that seamlessly integrate sensing and actuation directly within structural components.

The Technology

An OSU engineer has developed an additive manufacturing platform that fabricates structural components with embedded sensing and actuation functionality in a single process. The system deposits a thermoplastic matrix infused with functional materials while simultaneously applying an electric field during printing to tailor material properties in situ. This enables the formation of distributed, integrated sensor networks within the structure. By combining material deposition and functionalization within one manufacturing step, the approach produces seamless, multifunctional composites with embedded intelligence and customizable performance characteristics.

Commercial Applications

• Aerospace structural components with embedded health monitoring
• Automotive body panels with integrated sensing/actuation
• Smart infrastructure materials for real-time stress monitoring
• Advanced robotics and adaptive structures with self-sensing capabilities

Benefits/Advantages

• Single-step fabrication: Integrates sensors directly during manufacturing, eliminating secondary assembly
• Enhanced reliability: Embedded components reduce failure points associated with adhesives or fasteners
• Design flexibility: Enables custom sensor placement, density, and orientation within complex geometries
• Multifunctional performance: Combines structural integrity with sensing, actuation, and potential energy harvesting capabilities